ims_introduction_2015

The National Science FoundationIndustry/University Cooperative Research Center for Intelligent Maintenance Systems

NSF I/UCRC Since 2000

University of CincinnatiBaldwin Hall 560 Cincinnati, OH 45221-0072

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Introduction & Overview

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THE IMS CENTER

The IMS Center is a leading NSF Industry/University Cooperative Research Center (I/UCRC) in the area of Prognostics and Health Management (PHM). The Center has over twelve years of experience in developing and delivering PHM solutions for a wide-range of applications. IMS Centers mission is to enable products and systems to achieve and sustain near-zero breakdown performance, and transform maintenance data to useful information for improved productivity and asset life-cycle utilization. Since its inception, the Center has conducted over 100 successful industry and NSF supported projects, and has attracted over 80 members from all across the globe. The IMS Center was recently identified as the most economically impactful I/UCRC in NSFs recent study titled Measuring the Economic Impacts of the NSF Industry/University Cooperative Research Centers Program: A Feasibility Study. According to this study, the Center delivered its members a $846.7 Million in combined benefits over the last ten years.

INTERNATIONAL MEMBERS AND COLLABORATORS

Over the past twelve years, the IMS Center has worked with over 80 members from over 10 countries, including the US, Taiwan, Japan, China, Germany, Brazil, Finland, Spain, Belgium and France. In addition, the Center has collaborated with research institutions and organizations throughout the world. These collaborations give the Center a global perspective, which further broadens the potential applicability of its solutions, and enhances the development of the Centers researchers and staff.

IMS CENTER MEMBERSHIP

There are two types of IMS Membership: full and affiliate. Full members are companies or organizations with more than 500 employees and pay a membership fee of $40,000 annually; affiliate members have less than 500 employees and pay $12,000 annually. All members enjoy over a 30 to 1 leveraging ratio, and the opportunity to develop specific research projects with the center, based on their interests. Membership is the highest level of collaboration.

SELECTED MEMBERSHIP BENEFITS

IMS technologies & methodologies Company-specific projects IMS researchers for internships

Consulting & training opportunities Share best practices & experiences Extensive networking opportunities




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CORE TECHNOLOgy

Health AssessmentLogisitic Regression Neural Networks

Statistical Pattern Recognition Gaussian Mixture Model

Self-organizing Maps Atuo-Associative Neural Network

Signal Processing & Feature Extraction

Time Domain Analysis Wavelet Analysis

Frequency Domain Analysis Principal Component Analysis

Time-frequency Analysis Expert Extracted Features

Health DiagnosisTime Domain Analysis Wavelet Analysis

Time-frequency Analysis Expert Extracted Features

Performance PredictionAutoregressive Moving Average Match Matrix

Recurrent Neural Network Trajectory Similarity-based

The Watchdog Agent is a collection of intelligent software tools developed by the IMS Center that can be customized for monitoring equipment and systems in many diverse applications. Monitoring in this regard can refer to health or condition assessment, fault detection and performance prediction, among others. Monitoring results can be used in an enterprise resource planning system to ensure the appropriate preventative actions are taken before failures can occur, optimizing maintenance scheduling and resulting in extensive cost savings. The Watchdog Agent-enabled monitoring process begins with the identification of critical equip-ment. Sensors and data acquisition systems accumulate raw performance data from this equipment. Features are then extracted using signal processing tools. These features are then analyzed using appropriate tools specialized for health and performance assessment. When the performance of the monitored equipment falls below a defined threshold, fault diagnosis tools can determine the specific fault type and location. If data from previous operations exists, performance degradation can be further analyzed by prediction tools to determine when potential failures will occur, thus making the Watchdog Agent a transformational technology for pre-dicting and preventing failures for worry-free uptime.

WATCHDOg AgENT TOOLS




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WATCHDOg AgENT OVERVIEW




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NEW TECHNOLOgIES - CLOUD-BASED PROgNOSTICS

The IMS Center has developed a cloud-based solution to monitor the health of industrial robots using torque signals. This system is designed to be scalable, and to require little to no additional instrumentation. Beyond industrial robots, this solution could be deployed for many different applications that involve a large number and/or widely distributed assets. A similar solution for bearing health monitoring has also been developed that integrates the Centers virtual bearing concept.




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NEW TECHNOLOgIES - MOBILE HEALTH MONITORINg APPLICATIONS

The development of the Centers cloud-based pronositcs platform has enabled the creation of the Centers first mobile app-based health monitoring solution. The IMS Centers Mobile Health Monitoring Application can provide users with flexibility as well as functionality. This App presents a global view of the users facility or production line while also allowing the user to drill down to see the health status of each individual machine and each individual component being monitored.

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NOTIFICATIONS LOGIN SCREEN PLANT VIEW ASSET VIEW COMPONENT VIEW




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PAtEnt titlE PAtEnt numbEr inDuStry / APPlicAtionmethods for Prognosing mechanical Systems This Patent was awarded for novel methods for predicting when a failure will occur in a mechanical system based on extracting features from measurement data and selecting a prediction model based on the degradation status of the mechanical system and a reinforcement learning model.

US 8,301,406 Manufacturing and Industrial Assets and Systems

turbine-to-turbine Prognostics technique for Wind Farms This patent was awarded for novel methods for predicting the remaining-useful-life of a wind turbine or turbine component based on the performance of wind turbines within a clus-ter of turbines. These clusters are established based on performance metrics within a turbine farm, as well as environmental conditions, age, historical information, etc.

US 13/674,200 Wind Turbine Farms and other Mechanical Fleet Systems

methods and Systems for Energy Prognosis This patent was awarded for novel methods for determining and predicting the health condi-tion and operating performance of a system based on non-intrusive power consumption measurements.

US 20110066391 Manufacturing and Industrial Assets and Systems

IMS CENTER PATENTS




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PAtEnt titlE PAtEnt numbEr inDuStry / APPlicAtion

method and System for Electric Vehicle battery Prognostics and Health management This patent was awarded for a novel system for managing the mobility of an electrically-powered vehicle. This system is based upon inputs from a network of sensors that provide details about the operating condition of the vehicle as well as the ambient and environmental conditions. The estimates and prediction of mobility is displayed for the user for improved decision making.

US 20120296512 INT PCT/US12/35136

Electric Vehicles and Autonomously Guided Vehicles

method and System for Prognostics & Health management based on cloud computing This provisional patent was filed based on a novel method for assessing and predicting health and performance of a system utilizing advances in cloud computing, cyber-physical systems, modeling and prognostics.

US 61/509,945 (Provisional)

Manufacturing and Industrial Assets and Systems

Quick-test method for battery State of charge Estimation A provisional patent application has been submitted for a novel method for rapidly test-ing and determining the initial quality and potential life-cycle of a battery.

Provisional Patent Battery Manufacturing and Electric Vehicles

IMS CENTER PATENTS




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AmD cEntEr imPActS mEmbEr imPActS GrEAtEr imPActSThe IMS Centers expe-rience with AMD has enabled its researchers to expand the applicabil-ity of IMS technologies and to acquire additional research opportunities in the semiconductor in-dustry, including projects with ISMI, SiSoc and Ap-plied Materials.

Due to its involvement in the IMS Center, AMD was able to incorporate the Centers technologies into its production lines. In addition, AMD was able to hire Dr. Lei Yang, one of the Centers most gifted researchers. ISMI was able to generate interest in IMS work among its members.

The semiconductor indus-try is of great importance to the US economy. The work conducted at the Center in this area will continue to help the US maintain its competitive edge, bring about new innovations, and realize substantial cost-savings.

Semiconductor IndustryDomestic

2006 - 2008

GE Aviation cEntEr imPActS mEmbEr imPActS GrEAtEr imPActSThrough collaborations with GE Aviation in many aspects of intelligent manufacturing, IMS tech-niques have been validat-ed and demonstrated in test-beds equipped with cutting-edge technologies. Researchers have been able to gain work experi-ence in a global corpo-rate environment while understanding the role of resarch in industry.

GE aviation has quickly integrated IMS smart machine techniques into their engine production process. This will make GEs competitive advan-tages sustainable in global markets. Several IMS stu-dents have been hired by GE business and research centers.

This collaboration sets a good example for trans-ferring scientific and technological research to real production ben-efits. In addition, many research developments and techniques have been published and patented, broadening the impact of this work beyond the Cen-ter and its members.

Aviation Industry

Domestic

2007 - Present

MEMBER IMPACT HIgHLIgHTS




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Harley- Davidson

cEntEr imPActS mEmbEr imPActS GrEAtEr imPActSThis collaborative effort resulted in the integra-tion of Watchdog Agent prognostics platform into an existing indus-trial monitoring system. A standardized approach for integration of IMS tech-nologies has been estab-lished based on this work, giving the Center the abil-ity to rapidly deploy its technologies on multiple platforms.

The integration of the Watchdog Agent platform made possible real-time health moni-toring and prognostics for multiple networked machines, which resulted in a more cost effective production line at Harley-Davidson motor company, as indicated in the article Harley-Davidson: Born to be Predictable in Lean Tools for Maintenance & Reliability magazine.

The achievements made in working with Harley-Davidson can be applied to most of large scale factories with a number of machine tools and similar machines. The techniques developed impact the field of enterprise asset management by providing as solution for acquiring accurate machine health information.

Manufacturing ProcessDomestic

2001 - 2008

KomAtSu cEntEr imPActS mEmbEr imPActS GrEAtEr imPActSThe advance techniques developed in collaboration with Komatsu established a new area for the applica-tion of prognostic tech-nique, which has helped IMS attract more diverse members and deliver additional benefits to its current members.

The developed techniques through collaboration with the IMS Center have given Komatsu the ability to transform data into information and accurate, timely decisions. In addi-tion, through the hosting of a Komatsu engineer, the IMS Center was able to further disseminate its technologies and methods throughout Komatsus business units.

IMS members from US are able to learn more recent prognostic efforts made by their global competi-tors. The methodology de-veloped can be leveraged in many industries with widely distributed as-sets, such as automotive, heavy-duty construction equipment and mining equipment, among others.

Vehicle Telematics

International

2005 - 2008




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P&G cEntEr imPActS mEmbEr imPActS GrEAtEr imPActSA series of collaboration projects with P&G has enabled the IMS Center to extend prognostics research beyond tradi-tional equipment-based techniques to high speed complex production pro-cess applications. Another result of this project is that prognostic techniques developed by the Center have been validated in a commercial production control system, exhibiting that these techniques are robust and reconfigurable for multiple applications.

P&G has made consider-able efforts to realize process-oriented quality improvement by employ-ing digitalized information in the production envi-ronment. A large amount of investment has been placed i advanced vision/sensor technology to inspect crucial processes. It is the IMS tools provide a systematic solution for information handling and decision making. These tools are able to save the company nearly $10,000,000 per year.

The successful story of the collaboration proves that for process-oriented man-ufacturing industry the automation of information handling can dramatically improve productivity and product quality. Advanced data analysis tools and systematic design of analysis agents can play a crucial role in the infor-mation evolution

Manufacturing ProcessDomestic

2006 - Present

Pmc cEntEr imPActS mEmbEr imPActS GrEAtEr imPActSWith PMC, access to real-world data machine tool manufacturer Chevalier enabled the advancement of the Watchdog Agent tools. From a laboratory prototype, a complete machine tool monitoring system was developed and demonstrated. The use of fixed cycle feature test (FCFT) in this project, has informed projects with other companies including GE, TechSolve, Nissan, etc.

As a machine tool re-search institute in Taiwan, PMC was able to help demonstrate and educate machine tool suppliers and manufacturers how PHM can be developed and implemented in order to improve their equip-ment uptime and add value to their customers.

The adoption of PHM systems on the produc-tion floor has been slow and gradual thus far. The continuous validation and improvement can hasten the adoption process so that both manufacturers and customers can benefit from the added value that PHM delivers.

Machinery

International

2006 - Present




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SiEmEnS cEntEr imPActS mEmbEr imPActS GrEAtEr imPActSUnder the collaboration with SIEMENS TTB, The IMS Center developed a reconfigurable Plug-n-Prognose black box which can be easily and effectively used for prac-titioners to assess and predict the performance of critical components. A patent was awarded for this unique technology.

Due to collaboration with IMS Center, Siemens was able to develop a new service for its customers, strengthening SIEMENS product in the competitive market. In addition, SIE-MENS hired Dr. Leo Liao, one of the Centers most gifted researchers.

The patented technol-ogy provides prognostics information for rotary machinery components with minimum human intervention. Commer-cialization of such tech-nologies further brings attention to the benefits of PHM integration.

Machinery

International

2007 - 2009

toyotA cEntEr imPActS mEmbEr imPActS GrEAtEr imPActSThe Toyota facility (TMMK) in Lexington, KY has provided the Center with several real-world testbeds involving such critical assets as compres-sor and industrial robots, in order to validate Watch-dog Agent tools and algorithms. The company setup a robot test cell within their production floor, as well as allocating two robots for experimen-tation that were used by IMS researchers.

With the IMS collabora-tion, Toyota was able to upgrade their com-pressors with the surge protection and avoidance capability. This function-ality allowed the com-pany to save $50,000 on energy expenses annu-ally. With regard to the robot project, production floor health maps were developed in order to determine production bottlenecks to prioritize maintenance activities.

As companies push for reduction in carbon emis-sions, poor energy con-sumption due to degrad-ing/inefficient equipment performance is critical area that can be inves-tigated. With the use of Watchdog Agent tools, such energy inefficient equipment can be identi-fied and controlled.




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north America

21st Century Systems Chevron GE Aviation Inteligistics Rockwell

Advantech Cisco Genex ITW SCK

API Coherix GM Johnson Controls Siemens TTB

Applied Materials Daimler-Chrysler Goodyear Kistler Spirit Aero

ARL Eaton Harley-Davidson McKinsey & Co. Toyota

Avetec EDAptive Honeywell Montronix United Technologies

Boeing ETAS HRL National Instruments USPS

BorgWarner Festo Idaho Natl Lab P&G We Energies

Bosch Ford Ingersoll Rand Prometec Woodward

Caterpillar FTI Intel Parker Hannifin TechSolve

South America SENAI-CETA

Europe Alstom Transport FMTC FORCAM KONE Tekniker

ASiA

AITRI Delta Electronics ITRI OMRON Tongtai

Baoshan Steel GBS Komatsu PMC Toshiba

Beijing Shenzhou HIWIN MIRDC Samsung

CEI Hitachi Mitsubishi Shaanxi Auto

CEPREI IDEAS (III) Nissan Sinovel

INTERNATIONAL CURRENT AND FORMER IMS MEMBERS




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INTERNATIONAL COLLABORATORS

Country Institution Institution MOU

IMS Member

Professor Activity

Joint Funding

Personnel Exchange

Australia CIEAM X

Australia Queensland University of Technology X

Brazil SENAI Satellite Center X X

Brazil Universidade Federal do Rio Grande do Sul X X

Canada University of Toronto X

China BUAA X X

China Beijing University of Chemical Technology X X

China China University of Petroleum-Beijing X

China North China Electrical Power University X

China Shanghai Jiao Tong University X X X X

China Tsinghua University X

China Xian Jiao Tong University X X

Egypt Nile University X

France Universite de Metz X

Germany Technische Universitt Berlin X X

Germany University of Magdeburg X

Hongkong City University of Hongkong X

Hongkong Polytechnic University of Hongkong X

Japan University of Tokyo X

Norway University of Stavenger X

Singapore SIMTech Satellite Center X X

Sweden Lulea University X X

Switzerland cole Polytechnique Fdrale de Lausanne X X

Taiwan Industrial Technology Research Institute X X

Taiwan National Taiwan University X

Taiwan National Taiwan University of S&T X

Taiwan National Yunling University of S&T X X

Taiwan Precision Machinery R&D Center X X

UK University of Manchester X

UK Cranfield University X




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THANK yOU!

CONTACT USFor more inforamation on becoming a member and for updates on exciting new developments at the IMS Center.

Jay LeeOhio Eminent ScholarL.W. Scott Alter Chair ProfessorDepartment of Mechanical & Materials EngineeringUniversity of CincinnatiDirectorNSF Industry/University Cooperative Research Center forIntelligent Maintenance Systems (IMS)

+1.513.556.2493 Tel+1.513.446.3390 Fax

[email protected]

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